EP3140704B1 - Automatisierungsverwaltungsschnittstelle - Google Patents

Automatisierungsverwaltungsschnittstelle Download PDF

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Publication number
EP3140704B1
EP3140704B1 EP15725154.7A EP15725154A EP3140704B1 EP 3140704 B1 EP3140704 B1 EP 3140704B1 EP 15725154 A EP15725154 A EP 15725154A EP 3140704 B1 EP3140704 B1 EP 3140704B1
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EP
European Patent Office
Prior art keywords
data
display
machine
time
feature
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EP15725154.7A
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English (en)
French (fr)
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EP3140704A1 (de
Inventor
David Jingqiu Wang
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Beet Inc
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Beet Inc
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    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00—Programme-control systems
    • G05B19/02—Programme-control systems electric
    • G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
    • G05B19/048—Monitoring; Safety
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B11/00—Automatic controllers
    • G05B11/01—Automatic controllers electric
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00—Programme-control systems
    • G05B19/02—Programme-control systems electric
    • G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
    • G05B19/042—Programme control other than numerical control, i.e. in sequence controllers or logic controllers using digital processors
    • G05B19/0423—Input/output
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00—Programme-control systems
    • G05B19/02—Programme-control systems electric
    • G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
    • G05B19/042—Programme control other than numerical control, i.e. in sequence controllers or logic controllers using digital processors
    • G05B19/0426—Programming the control sequence
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00—Programme-control systems
    • G05B19/02—Programme-control systems electric
    • G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
    • G05B19/409—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by using manual data input [MDI] or by using control panel, e.g. controlling functions with the panel; characterised by control panel details or by setting parameters
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00—Programme-control systems
    • G05B19/02—Programme-control systems electric
    • G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00—Programme-control systems
    • G05B19/02—Programme-control systems electric
    • G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
    • G05B19/4183—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by data acquisition, e.g. workpiece identification
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B23/00—Testing or monitoring of control systems or parts thereof
    • G05B23/02—Electric testing or monitoring
    • G05B23/0205—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults
    • G05B23/0208—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterized by the configuration of the monitoring system
    • G05B23/0216—Human interface functionality, e.g. monitoring system providing help to the user in the selection of tests or in its configuration
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B23/00—Testing or monitoring of control systems or parts thereof
    • G05B23/02—Electric testing or monitoring
    • G05B23/0205—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults
    • G05B23/0259—Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterized by the response to fault detection
    • G05B23/0267—Fault communication, e.g. human machine interface [HMI]
    • G05B23/0272—Presentation of monitored results, e.g. selection of status reports to be displayed; Filtering information to the user
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/10—Plc systems
    • G05B2219/15—Plc structure of the system
    • G05B2219/15126—Calculate duration of cycle
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/20—Pc systems
    • G05B2219/25—Pc structure of the system
    • G05B2219/25387—Control sequences so as to optimize energy use by controlled machine
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/20—Pc systems
    • G05B2219/25—Pc structure of the system
    • G05B2219/25407—Delay between operations
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/31—From computer integrated manufacturing till monitoring
    • G05B2219/31368—MAP manufacturing automation protocol
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/31—From computer integrated manufacturing till monitoring
    • G05B2219/31472—Graphical display of process
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/35—Nc in input of data, input till input file format
    • G05B2219/35472—Mode selection
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/39—Robotics, robotics to robotics hand
    • G05B2219/39447—Dead man switch
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P80/00—Climate change mitigation technologies for sector-wide applications
    • Y02P80/10—Efficient use of energy, e.g. using compressed air or pressurized fluid as energy carrier
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Definitions

  • the present disclosure relates generally to operating and managing automated equipment, including collecting and capturing automation data using an automation controller in communication with a computing device.
  • US2009/164933A1 discloses methods and apparatus to present recipe progress status information.
  • a disclosed example method involves displaying a user interface screen associated with a recipe being executed in a process control system.
  • the recipe includes a plurality of process phases.
  • a plurality of process stage progress indicators are displayed in the user interface screen in an arrangement representative of the process flow of the recipe.
  • Each of the process stage progress indicators is representative of at least one of the process phases of the recipe.
  • a first one of the process stage progress indicators is indicative of a progress of at least one of the process phases.
  • the first process stage progress indicator is updated in substantially real-time based on information received from the process control system.
  • US2012/079407A1 discloses methods and apparatus to display process control information.
  • An example method includes receiving in a processor a first status of a first mode element, the first mode element indicating a current operating condition of an object of a process control device, receiving in the processor a second status of a second mode element, the second mode element indicating a desired operating condition of the object of the process control device, determining a mode of the object based on the first status and the second status, the mode indicating a condition of the object of the process control device, and displaying the mode of the object of the process control device within a user interface as a graphic.
  • a facility may include multiple machines. Each machine can be controlled by a programmable logic controller (PLC) or similar controller connected to multiple machine elements, power sources and sensors of the machine.
  • PLC programmable logic controller
  • the controller in communication with the sensors receives sensor inputs to the controller indicating condition states of the various elements.
  • the controller may be programmed to scan at a predetermined frequency through a scan cycle, defined for example, by a sequence of operations (SOP) to be performed by the elements of the machine, and, based on the sensor inputs and condition states received by the controller, selectively energize the power sources to actuate the elements to perform operations defined by the program.
  • SOP sequence of operations
  • Each machine and its associated controller may be operated independently from each other machine. Some processes use manually controlled tools, such as pneumatic torque wrenches, where consolidation of process data may be difficult.
  • An automated operating system which accumulates data and inputs from various elements, machines, and facilities of an enterprise operating the AOS, and/or over various operating time periods, and analyzes the accumulated data and inputs using a server to identify issues, trends, patterns, etc. which may not be identifiable by independent machine controllers of the machines in the enterprise, for example, where such issues may result from interactions of multiple inputs which are outside the scope of inputs controlled by or analyzed by any individual one of the machine controllers, and/or which may be identifiable only by a combination of inputs from multiple machine, multiple time periods such as operating shifts, and/or by a combination of inputs to determine cumulative issues within a production line, a zone, a group of common elements or common machines, etc.
  • the AOS can be used to identify, to initiate responses to, to manage and/or to prevent issues using the collective resources of the enterprise in which the AOS operates.
  • the AOS described herein is advantaged by the capability to generate a plurality of differently configured data displays generated from a plurality of corresponding display templates populated with real time data which can be displayed to a user in real time, on a user interface of a user device, to allow real time monitoring of the operation, machine, etc. defining the data display being viewed by the user.
  • Differentiation of certain data features of the data display provides immediate visual recognition by the user/view of the condition state and/or alert status of a differentiated data feature.
  • the differentiated data feature may be visually differentiated, for example, by color, pattern, font, lighting, etc. for efficient viewing.
  • the data display may be activated by a touch input to the touch screen to display additional information, for example, in a pop-up window, for convenient and real time viewing by the user/viewer.
  • the invention defines a system and method for controlling automation according to claims 1 and 8.
  • FIG. 1 shows an automation operating and management system 10 for controlling systems, machines, and elements operating within an enterprise 12.
  • the automation operating and management system 10 may be referred to herein as an automation operating system (AOS).
  • AOS automation operating system
  • the enterprise 12 includes an enterprise server L4, which may also be referred to herein as a fourth layer server, for receiving and consolidating data from multiple facilities 14 (shown in the example of FIG. 1 as facilities 14A...14x and referred to herein collectively as facilities 14) within the enterprise 12.
  • Each of the facilities 14 includes a facility server L3, which may also be referred to herein as a third layer server, for receiving and consolidating data from multiple facility systems SY (shown in the example of FIG. 1 as systems SY1...SY m and referred to herein collectively as systems SY) within each of the facilities 14.
  • Each facility server L3 is in communication with the enterprise server L4.
  • At least one of the facility systems SY in each of the facilities 14 (shown in the example of facility 14A as system SY1) includes multiple machines 16 (shown in the example of FIG. 1 as machines 16A...16 y and referred to herein collectively as machines 16).
  • the machines 16 can be any machines that perform coordinated operations including automated machines.
  • the machines 16 can be machines such as automated machines performing operations in a manufacturing plant and/or an assembly facility.
  • the enterprise server L4 can be embodied as one or more computer devices having a processor 94 and a memory 92, some of which is computer-readable tangible, non-transitory memory arranged on a printed circuit board or otherwise available to the processor 94. Instructions embodying the methods described herein may be programmed into memory 92 and executed as needed via the processor 94 to provide functionality of the AOS 10 as described herein.
  • the memory 92 may include, by way of example, sufficient read only memory (ROM), optical memory, flash or other solid state memory, and the like.
  • Transitory memory such as random access memory (RAM) and electrically-erasable programmable read-only memory (EEPROM) may also be included, along with other required circuitry (not shown), including but not limited to a high-speed clock, analog-to-digital (A/D) circuitry, digital-to-analog (D/A) circuitry, current/voltage/temperature/speed/position sensing circuitry, a digital signal processor, and any necessary input/output (I/O) devices and other signal conditioning and/or buffer circuitry.
  • RAM random access memory
  • EEPROM electrically-erasable programmable read-only memory
  • the enterprise server L4 can include a communications interface 96 for communication with other controllers and/or servers in the enterprise 12, including for example, for communication with each of a third layer server L3, a second layer controller L2 and a first layer controller L1 of the enterprise 12.
  • the fourth layer (enterprise) server L4, third layer servers L3, second layer controllers L2 and first layer controllers L1 can be in communication with each other via a network 80, which may be a wired or wireless network.
  • AOS 10 can include a data storage memory 90 which can be used to store data received from one or more of the fourth layer server L4, third layer servers L3, second layer controllers L2 and first layer controllers L1.
  • the data storage memory 90 may be accessed via the network 80 and/or may be external to the enterprise 12, for external data storage.
  • the data storage memory 90 can be accessible via the enterprise server L4 and/or via the network 80.
  • the data storage memory 90 can include, by way of example, sufficient read only memory (ROM), optical memory, flash or other solid state memory, and the like to store data received from the enterprise 12.
  • Transitory memory such as random access memory (RAM) and electrically-erasable programmable read-only memory (EEPROM) may also be included, along with other required circuitry (not shown), including but not limited to a high-speed clock, analog-to-digital (A/D) circuitry, digital-to-analog (D/A) circuitry, a digital signal processor, and any necessary input/output (I/O) devices and other signal conditioning and/or buffer circuitry.
  • RAM random access memory
  • EEPROM electrically-erasable programmable read-only memory
  • the data storage memory 90 can comprise a distributed memory network, for example, including memory 92 of the enterprise server L4, memory (not shown) of one or more of the facility servers L3, etc., which can be accessed as part of the data storage memory 90, for example, via the network 80.
  • AOS 10 can further include one or more user devices (shown in the example of FIG. 1 as user devices Ul...Uw and referred to herein collectively as user devices U) in communication with the enterprise 12, via a wired connection or a wireless connection, for example, via the network 80.
  • a user device U can be a computing device such as a personal computer, tablet, laptop, smart phone, personal digital assistant, or other personal computing device for viewing information including data related to and/or provided by the enterprise 12.
  • the user device U can display a machine control interface for one or more of the machines 16.
  • the user device U can include a user interface 74 such as a touch screen for interacting with the information and data of the enterprise 12 and/or for controlling the machine 16 via the machine control interface.
  • each of the machines 16 includes a second layer controller L2 and one or more first layer controllers L1.
  • Each of the machine controllers L2 (shown in the example of FIG. 1 as machine controllers L2A...L2 y and referred to herein collectively as machine controllers L2) within a respective facility 14 are in communication with the respective facility controller L3 for that facility 14.
  • a second layer controller L2 may also be referred to herein as a machine controller.
  • Each machine controller L2 of a respective machine 16 is in communication with the first layer controllers L1 of that respective machine.
  • a first layer controller L1 may be referred to herein as a base layer controller.
  • the machine controllers L2 and the base layer controllers L1 can each perform specific functions in controlling and monitoring the operation of the machine 16.
  • Each machine controller L2 and each base layer controller L1 can be embodied as one or more computer devices having a processor and memory, some of which is computer-readable tangible, non-transitory memory arranged on a printed circuit board or otherwise available to the processor. Instructions may be programmed into the memory of each of the machine controllers L2 and each of the base layer controllers L1 and executed as needed via the processor of the respective controller L2, L1 to provide the control functionality over the machines 16 and/or elements E within the control of each respective machine controller L2 and/or each respective base layer controller L1.
  • the memory of each machine controller L2 and each base layer controller L1 can include, by way of example, sufficient read only memory (ROM), optical memory, flash or other solid state memory, and the like.
  • Transitory memory such as random access memory (RAM) and electrically-erasable programmable read-only memory (EEPROM) may also be included, along with other required circuitry (not shown), including but not limited to a high-speed clock, current/voltage/temperature/speed/position sensing circuitry, analog-to-digital (A/D) circuitry, digital-to-analog (D/A) circuitry, a digital signal processor, and any necessary input/output (I/O) devices and other signal conditioning and/or buffer circuitry.
  • Each machine controller L2 and each base layer controller L1 can include one or more monitoring, measuring and/or control devices for monitoring, measuring and/or controlling the machines 16 and/or elements E within the control of each respective machine controller L2 and/or each respective base layer controller L1.
  • Each machine 16 includes a plurality of stations ST (shown in the example of FIGS. 1 and 2 as stations ST1...ST n and referred to herein collectively as stations ST) for performing an operational cycle of the machine 16, where the operational cycle includes operations of the machine 16 performed in a predetermined sequence controlled by the base layer controller L1 and/or the machine controller L2 of the machine 16.
  • the predetermined sequence in which the operations in the operational cycle is performed can be defined by a sequence of operations 39 and/or a portion of a sequence of operations 39 defined for that machine 16 by the machine controller L2 of the machine 16. It would be understood that the machine 16 would, in operation, repeatedly perform the operational cycle comprising the sequence of operations 39 under control of the machine controller L2 and/or the base layer controller L1.
  • Each of the base layer controllers L1 controls operations performed by at least one of the stations ST in communication with the respective base layer controller L1.
  • each station ST includes one or more elements E (shown in the example of FIG. 2 as elements E1...E p and referred to herein collectively as elements E), for performing various operations and/or tasks of the respective station ST.
  • examples of elements E used to perform the various operations of a manufacturing and/or assembly operation performed by a machine 16 and/or station ST can include clamps, cylinders, collets, pins, slides, pallets, etc., where the examples provided herein are non-limiting.
  • Each station ST further includes one or more power sources P (shown in the example of FIG. 2 as power sources P1...P r and referred to herein collectively as power sources P), for providing power to one or more elements E and for selectively energizing a respective element E in response to a signal from the base layer controller L1.
  • Each station ST further includes one or more sensors S (shown in the example of FIG. 2 as sensors S1...S q and referred to herein collectively as sensors S), for sensing a state of at least one of the elements E and the power source P of the station ST and providing an input to the base layer controller L1 indicating the state sensed by the sensor S.
  • a state which may be referred to as a condition state or as a condition, as used herein, refers to a state of the object, a condition, a status, a parameter, a position, or other property being monitored, measured and/or sensed.
  • condition states including cycle start time, cycle stop time, element start time, element travel, element stop time, position of an element or object, a dimensional measurement or parameter of an object which can include a dimensional measurement of a feature of an element E, a feature of a machine 16, a feature of a workpiece (not shown) to which an operation is being performed by a machine 16 or an element E, a condition of one or more of an element E, machine 16 or workpiece, or a condition of the environment within the facility 14.
  • a condition state could further include for example, operating conditions such as on, off, open, closed, auto, manual, stalled, blocked, starved, traveling, stopped, faulted, OK, good, bad, in tolerance, out of tolerance, present, not present, extended, retracted, high, low, etc., and can include for example, a measure of a physical property such as chemistry, temperature, color, shape, position, dimensional conditions such as size, surface finish, thread form, a functional parameter such as voltage, current, torque, pressure, force, etc., such that it would be understood that the terms state, condition, condition state and/or parameter as describing inputs to the AOS 10 are intended to be defined broadly.
  • a sensor S may be configured as a limit switch, a proximity switch, a photo eye, a temperature sensor, a pressure sensor, a flow switch, or any other type of sensor which may be configured to determine if one or more states are met during operation of the automated system 10, to sense one or more parameters during operation of the automated system 10, and to provide an output to the at least one automation controller, such as the base layer controller L1 and/or the machine layer controller L2, which is received by the controller L1, L2 as an input corresponding to the state determined by the sensor S.
  • the at least one automation controller such as the base layer controller L1 and/or the machine layer controller L2
  • the sensor S output may be configured, for example, as a signal provided to the base layer controller L1 and/or to the machine layer controller L2, and received by the base layer controller L1 and/or to the machine layer controller L2 as an input including input data.
  • the sensor S may be configured to provide a discrete or bit-form output.
  • the sensor S may be configured as an analog sensor and may provide an analog output signal corresponding to one or more of multiple states of a element E or a group of elements E associated with the sensor S, or one or more of multiple states of an environment of the machine 16 and/or the environment of the facility 14 including the machine 16.
  • the sensor inputs and/or input data received by controllers L1 and L2 can be communicated, for example, via controller L2, to one or more of the servers L3 and L4 and/or stored in data storage memory 90.
  • the predetermined sequence of operations in the operational cycle can be defined by a sequence of operations 39 and/or a portion of a sequence of operations 39 defined for that machine 16 by the machine controller L2 of the machine 16.
  • the machine controller L2 can perform the functions of the machine controller L2 and the base layer controllers L1, such that the machine 16 can be configured without the base layer controllers L1.
  • the machine 16 would, in operation, repeatedly perform the operational cycle comprising the sequence of operations 39 under the independent control of the machine controller L2.
  • the controller functions may be divided between the base layer controllers L1 and the machine controller L2, with the base layer controllers L1 functioning as low level controllers and the machine controllers L2 functioning as a high level controller coordinating the operation of the base layer controllers L1 within the machine 16.
  • the machine 16 would, in operation, repeatedly perform the operational cycle comprising the sequence of operations 39 under the control of the machine controller L2 and the base layer controllers L1, where the machine controller L2 acts as a data collector collecting the condition state data for each of the elements E of the machine 16 from each of the respective base layer controllers L1, and acts as a local area controller to coordinate and control the interaction of the base layer controllers L1 with each other.
  • each base layer controller L1 within the machine 16 is in communication with each other base layer controller L1 within the machine 16 and with the machine controller L2 to communicate condition states of each of the elements E controlled by that respective base layer controller L1, such that each base layer controller L1 can execute control actions of the respective elements E under the control of the respective base layer controller L1 in response to the condition state data received from the other base layer controllers L1 in the machine 16.
  • the enterprise 12 shown in FIGS. 1 and 2 may be a production enterprise including a plurality of manufacturing and/or assembly facilities 14, such as facilities 14A, 14B and 14C.
  • the facilities 14A, 14B and 14C may be co-located within the production enterprise 12, for example, each of the facilities 14A, 14B and 14C may be sub-factories or assembly lines co-located in a larger building defining the production enterprise 12.
  • each of the facilities 14A, 14B and 14C may be a stand-alone factory which may be geographically separated from each other and in communication with each other and the enterprise server 12, for example, via the network 80.
  • Facility 14A for illustrative purposes, is shown in additional detail in FIGS. 1 and 2 , and includes a facility server L3A which is in communication with multiple systems SY such as systems SY1, SY2 and SY3 operating in the facility 14A.
  • system SY1 includes manufacturing and/or assembly operations consisting of multiple machines 16 such as machines 16A, 16B, 16C, 16D and 16E.
  • machine 16A is shown in additional detail in FIG. 2 , consisting of multiple stations ST such as stations ST1 through ST10.
  • Machine 16A includes a machine controller L2A in communication with multiple base layer controllers L1 such as base layer controllers L1A, L1B and L1C.
  • Each of the base layer controllers L1A, L1B and L1C acts to control multiple stations ST according to instructions received from the machine controller L2A, to perform operations, for example, defined by a sequence of operations 39 stored in the machine controller L2A.
  • FIG. 1 As shown in FIG.
  • base layer controller L1A can control the operations of stations ST1, ST2, ST3, ST4 by selectively activating the power sources P1, P2 and P3 to selectively actuate elements E1, E2, E3 and E4.
  • the base layer controller L1A receives sensor outputs from the sensors S1, S2, S3 and S4 which indicate condition states, for example, of the elements E1, E2, E3 and E4.
  • the base layer controller L1A is in communication with base layer controllers L1B and L1C in the present example, and receives condition state input from base layer controllers L1B and L1C indicating the condition states of elements E5 through E10.
  • the base layer controller L1A selectively actuates the elements E1, E2, E3 and E4 according to instructions stored in the memory of the base layer controller L1A, inputs and instructions received from the machine controller L2A and in response to the condition states of the elements E1 through E10, in the present example, received by the base layer controller L1A.
  • the examples described herein and shown in FIGS. 1 and 2 related to machine 16A are illustrative and non-limiting.
  • each of the machines 16 controlled and/or managed by AOS 10 could include a machine controller L2, however could differ in including a base layer controller L1 and/or the number of base layer controllers L1 included in the machine 16, and could differ in the number, arrangement, function, etc. of the stations ST, elements E, sensors S and power sources P from the illustrative example of machine 16A shown in FIGS. 1 and 2 .
  • facility systems SY2 and SY3 shown in FIGS. 1 and 2 can operate in the facility 14A and can be operated and/or managed using the AOS 10 in a manner and/or to provide outputs which can affect the operations of system SY1 in facility 14A, including affecting the efficiency and/or downtime of the machines 16 included in the system SY1.
  • Each of the systems SY2, SY3 includes one or more servers (not shown, referred to herein as a SY server) which can be embodied as one or more computer devices having a processor and memory, some of which is computer-readable tangible, non-transitory memory arranged on a printed circuit board or otherwise available to the processor.
  • Instructions may be programmed into the memory of each SY server and executed as needed via the processor of the SY server to provide monitoring and/or control functionality over the facility operations within the control of the respective SY system.
  • the memory of the SY server can include, by way of example, sufficient read only memory (ROM), optical memory, flash or other solid state memory, and the like.
  • Transitory memory such as random access memory (RAM) and electrically-erasable programmable read-only memory (EEPROM) may also be included, along with other required circuitry (not shown), including but not limited to a high-speed clock, current/voltage/temperature/speed/position sensing circuitry, analog-to-digital (A/D) circuitry, digital-to-analog (D/A) circuitry, a digital signal processor, and any necessary input/output (I/O) devices and other signal conditioning and/or buffer circuitry.
  • Each of the systems SY2, SY3 can include one or more monitoring, measuring and/or control devices and/or sensors for monitoring, measuring and or sensing a state of the facility operations within the control of the respective SY system.
  • system SY2 can be a facility management system, which may be referred to herein as a facility infrastructure system SY2, for monitoring, measuring and/or controlling various factors of the infrastructure and operating environment of facility 14A, such as electrical power supply provided to the various power sources P, water supply provided to hydraulic and/or coolant systems within the facility 14A and/or coolant systems related to the machines 16, compressed air supply provided within the facility 14A, for example, to pneumatic systems of the machines 16, to pneumatically operated elements E, and/or to pneumatically controlled manual tools such as pneumatic torch wrenches which may be used in manufacturing and/or assembly operations within the facility 14A.
  • a facility infrastructure system SY2 for monitoring, measuring and/or controlling various factors of the infrastructure and operating environment of facility 14A, such as electrical power supply provided to the various power sources P, water supply provided to hydraulic and/or coolant systems within the facility 14A and/or coolant systems related to the machines 16, compressed air supply provided within the facility 14A, for example, to pneumatic systems of the machines 16, to pneumatically operated elements E,
  • an increase in temperature of cooling water circulating in a cooling water jacket of a machine 16 may change the efficiency of heat transfer from a work area of the machine 16, affecting the tool life of the welding elements E in the machine 16 and/or the cooling rate of the welds being formed in a product welded by the machine 16.
  • variability in the voltage level of the incoming power supply provided to a power source P can affect the response time of a clamp element E activated by the power source P, thereby affecting the cycle time of the operation performed by the clamp element E.
  • system SY2 can monitor, measure, and/or control ambient conditions within the facility 14A, or within a portion of the facility 14A, such as temperature, humidity, etc.
  • the facility 14A may be portioned into multiple zones 98 such as zones 98A, 98B, 98C shown in FIG. 9 , where at least one of the machines 16 is located in each zone.
  • one of the zones 98A, 98B, 98C can include machines 16 which are performing operations sensitive to ambient temperature and/or humidity conditions, such as an electronics fabrication operation or a painting operation, such that variability in the ambient temperature and/or humidity in that zone may affect the quality of the product produced by the machines 16 in that area.
  • ambient temperature and/or humidity conditions such as an electronics fabrication operation or a painting operation
  • variability within facility controlled systems and conditions such as power supply, water supply, compressed air supply, temperature, humidity, etc.
  • System SY2 can transmit signals (inputs) to the facility server L3A indicating condition states of the various factors of the operating environment of facility 14A being monitored, measured, and/or controlled by the facility server L3A.
  • system SY3 can include production control and product assurance operations and can monitor, measure and/or control various factors of the production control and product assurance operations which impact the operation of manufacturing and production system SY1 of facility 14A.
  • the production control operations of system SY3 can monitor inventory levels (on order, in transit, in stock) of machine parts for the machines 16, which may include replaceable service parts (motors, etc.) sensors S (limit switches, etc.) and/or elements E which can include durable (reusable) elements such as clamps, cylinders, etc. and/or consumable (replaceable) elements E such as drills, taps, clamp pads, etc. required for a station ST to complete an operation and/or for the machine 16 to operate.
  • the production control operations of system SY3 can monitor inventory levels (on order, in transit, in stock) of vendor supplied (purchased) components and/or material which are provided to the machines 16, for example, as raw material or work pieces on which operations are performed by the machines 16, or are provided to the machines 16, for example, as components to be assembled with other components to form a finished assembly.
  • the product assurance operation for example, can monitor the condition of vendor supplier (purchased) components and/or materials and indicate the acceptance or rejection of the vendor supplied materials, which could affect the availability of that inventory to the machines 16.
  • the product assurance operation can measure and output a condition state of a component or raw material to the facility server L3 and/or to a machine controller L2 of a machine 16 processing the component or raw material, such that the machine 16 in response can adjust settings based on the measured condition state of the incoming component or raw material.
  • a machine 16 may be an oven to temper components made from raw material.
  • the machine 16 via the facility controller L3 can receive hardness data for the raw material from the product assurance system SY3 and adjust the tempering temperature of the oven based on the hardness of the raw material.
  • System SY3 can transmit signals (inputs) to the facility server L3A indicating condition states of the various factors of the operating environment of facility 14A being monitored, measured, and/or controlled by the facility server L3A.
  • the facility server L3A acts as a data collector within the AOS 10 for collecting the inputs received from the systems SY1, SY2 and SY3, and can analyze and use the accumulated data and inputs to identify and respond to operating conditions throughout the facility 14A, including implementing preventive actions to minimize downtime, efficiency losses and/or productivity losses, by controlling and modifying the operations within the facility 16A, which can include outputting commands to the machine controllers L2A through L2E and outputting commands to systems SY2 and SY3, for example, in response to condition states and inputs received from the machine controllers L2A through L2E and systems SY2 and SY3, to modify the operating conditions within the facility 14A, the sequence of operations 39 performed by the various stations ST, the machines 16 and/or stations ST used to perform one or more operations, etc., to improve efficiency, decrease and/or optimize power consumption within the facility, increase productivity, reduce or avoid downtime, etc.
  • the AOS 10 is advantaged by accumulating the data and inputs from multiple production (SY1) and non-production (SY2, SY3) systems and multiple machines within a facility 14, analyzing the accumulated data and inputs using a facility server L3 to identify issues which may not be identifiable by the independent machine controllers L2, for example where such issues may result from interactions of multiple inputs which are outside the scope of inputs controlled by any one of the machine controllers L2, and/or which may be identifiable only by combination of inputs from multiple sources (multiple machines 16, a machine 16 and system input from one or more of systems SY2, SY3, etc.), and using the AOS 10 to identify, action responses to, manage and/or prevent issues using the collective resources of the facility 14.
  • the enterprise server L4 acts as a data collector for the inputs and data received from the facility servers L3A, L3B and L3C.
  • the enterprise server L4 can analyze and use the accumulated data and inputs to control and modify the operations within one or more of the facilities 16A, 16B, 16C, 16D and 16E, including implementing preventive actions to minimize downtime, efficiency losses and/or productivity losses, by controlling and modifying the operations of one or more of the facilities 16A, 16B, 16C, 16D and 16E, in response to an issue or condition identified in one or more of the facilities 16A, 16B, 16C, 16D and 16E, which can include, for example, transferring production between facilities 16 in anticipation of or in response to a downtime event, to increase efficiency based on the operational condition of a machine 16 in one facility 14 as compared to an identical and/or substantially similar machine 16 in another facility 14, to respond to inputs received from the non-production systems SY2 and/or SY3 indicating for example, a
  • the AOS 10 is advantaged by accumulating the data and inputs from facilities 14, analyzing the accumulated data and inputs using the enterprise server L4 to identify issues which may not be identifiable by the independent facility servers L3, for example where such issues may result from interactions of multiple inputs which are outside the scope of inputs controlled by or received into any one of the facility servers L3, and/or which may be identifiable only by a combination of inputs from multiple facilities L4, and using the AOS 10 to identify, action responses to, manage and/or prevent issues using the collective resources of the enterprise 12.
  • facility 14A The examples described herein and shown in FIGS. 1 and 2 related to facility 14A are illustrative and non-limiting, and it would be understood that the facilities 14 other than facility 14A included in the enterprise 12 can each include at least one machine 16 configured similar to machine 16A to include a base layer controller L1 and a machine controller L2, however the number and configuration of each of the machines 16 may vary within a facility 14 and from one facility 14 to another facility 14, and each of the machines 16 may include elements E and sensors S arranged in stations ST other than those described for the example of machine 16A to perform operations other than those performed as described for machine 16A.
  • an enterprise 12 including facilities 14 such as manufacturing plants and/or assembly facilities is not intended to be limiting.
  • An AOS 10 as described herein can be applied to the control and management of any type of enterprise 12 including machines 16 performing coordinated operations, and as such it would be understood that the terms enterprise 12, facility 14, machine 16, element E and sensor S are intended to be defined broadly.
  • an enterprise 12 can be an amusement park including an AOS 10, where the facilities 14 and machines 16 are defined by different areas of the amusement park and the systems SY can include, for example, a security system for the amusement park and an infrastructure system (water, power, waste disposal, etc.) of the amusement park.
  • an amusement ride facility 14A can include machines 16 forming the amusement rides
  • an admission ticketing facility 14B can include machines 16 for receiving and securing payment for tickets
  • a dining facility 14C can include machines 16 for providing food service
  • a parking facility 14C can include machines 16 for receiving parking fees and monitoring and patrolling the parking area, etc.
  • an enterprise 12 including an AOS 10 may be a property development, such as an office building complex, where each facility 14 includes one or more buildings within the complex, and the machines 16 operating in each facility 14 include, for example, elevators, security cameras, heating and ventilation equipment, etc.
  • timing data collected from one or more of the elements E, stations ST and/or machines 16 within the enterprise 12 can be displayed as shown in FIG. 3 in a traditional sequence of operation (SOP) display format 33, and/or in a heartbeat display format 35 shown in FIG. 4 .
  • SOP sequence of operations
  • the sequence of operations 39 corresponding to the data being displayed is listed vertically (as shown on the page), and in the present example includes operations Op1 through Op9, with operation Op1 being performed by elements E1 and E2 of a machine 16, operation Op 2 being performed by elements E3 and E4, and so on.
  • a baseline cycle, e.g., the design intent cycle, for each of the operations Op1...Op9 in the SOP 39 is graphically shown by a baseline cycle indicator 29.
  • the actual cycle for each of the operations Op1...Op9 is graphically shown by an actual cycle indicator 31.
  • Each of the actual cycle indicators 31 may be color coded, e.g., displayed in a color defining the status of the cycle of that operation. In the example shown, the actual cycle indicators 31 are displayed in either a red or green color, with red indicating the actual cycle time is outside of a predetermined tolerance for the cycle of that operation, and green indicating the actual cycle time is within tolerance.
  • the sequence of operations (SOP) 39 corresponding to the data is displayed on the horizontal axis (as shown on the page) with the actual cycle time of each operation Op1...Op9 shown in heartbeat display format by an actual cycle time indicator 31, which may be color coded as previously described for FIG. 3 , to indicate whether the cycle time for each respective operation is within tolerance.
  • FIG. 4 further displays the heartbeat 88 of the sequence of operations, where the heartbeat 88 is determined, for example, as described in U.S. patent 8,880,442 B2 issued November 14, 2014 to the inventor.
  • the AOS 10 can include one or more user devices U (shown in the example of FIGS. 1 and 2 as user devices U...Uw and referred to herein collectively as user devices U) in communication with the data collected by the AOS 10, for example, via the network 80.
  • the user device U can be a portable computing device such as a personal computer, notebook, tablet, smart phone, personal data assistant, etc., including, as shown in FIG. 5 , a processor 76 and memory 78, some of which is computer-readable tangible, non-transitory memory arranged on a printed circuit board or otherwise available to the processor 76.
  • the memory 78 may include, by way of example, sufficient read only memory (ROM), optical memory, flash or other solid state memory, and the like.
  • Transitory memory such as random access memory (RAM) and electrically-erasable programmable read-only memory (EEPROM) may also be included, along with other required circuitry (not shown), including but not limited to a high-speed clock, location sensing circuitry, analog-to-digital (A/D) circuitry, digital-to-analog (D/A) circuitry, a digital signal processor, and any necessary input/output (I/O) devices and other signal conditioning and/or buffer circuitry.
  • the user device U can include a connector port 72 for connecting the user device to another device (not shown).
  • the user device U includes a communications interface which can be a wireless or wired interface, for connection of the user device U to the network 80 for communication with one or more of the controllers L1, L2, the servers L3, L4, another of the user devices U, and/or the data storage memory 90.
  • the user device U includes a graphical user interface (GUI) 74, which in a preferred example is a graphical touch screen, such that a user can provide input to the user device U, including commands, via the touch screen 74 and/or standard tool bars 82.
  • GUI graphical user interface
  • the graphical user interface 74 may also be referred to herein as a touch screen and/or as a user interface 74.
  • the user may monitor the data collected from one or more of the elements E and/or machines 16 in the enterprise 12, which may be displayed on the user device U as a machine control interface, as described in U.S. patent application 14/705,421 filed May 6, 2015 by the inventor, where the machine control interface can be defined by one of the machine controller L2, the facility server L3 and/or the enterprise server L4.
  • the machine control interface can be defined, at least in part, by a display template 13 7, such that the machine control interface can be as displayed on the user interface 74 can be a data display 138 as described herein.
  • the user may subscribe to receive alerts for one or more elements E and/or machines 16 being monitored by the user, where the alerts may be received by the user on the user device U as one or more of a text message, instant message, e-mail, or other alert indicator.
  • FIGS. 3, 4 , 5-6 and 10-20 show examples of data displays 138 which can be generated by a server, such as a facility server L3 and/or an enterprise server L4, for display on a user device U, by populating a display template 137 with data from AOS 10.
  • the display template 137 is shown populated with data, e.g., the display template 137 is illustrated by a data display 138 generated using the display template 137.
  • the data display 138 can be generated by the facility server L3 by populating a display template 137 with data collected from a machine 16 and/or data collected from a system SY, such as systems SY2, SY3, where the data is collected and stored to a memory, such as data memory storage 90, for use by the facility server L3 in generating the data display 138.
  • a plurality of display templates 137 can be stored on data memory storage 90 and retrieved by the facility server L3 to generate a corresponding data display 138 in real time.
  • the data memory storage 90 can be a standalone enterprise memory storage 90 as shown in FIG.
  • data memory storage 90 can include memory 92 of enterprise server L4, and/or memory included one or more of the facility servers L3.
  • Each display template 137 can be configured to display one or more data features 141, where a data feature 141 displays data collected from the machines 16 and/or systems SY.
  • a plurality of display templates 137 can be configured and stored in data memory storage 90 for use in generating a corresponding plurality of data displays 138.
  • the plurality of display templates 137 can include one or more display templates 137 for displaying data of each of a machine 16, a group of machines 16, a production line, a zone 98 within a facility 14 including at least one machine 16, a group of zones 98 such as zones 98A, 98B, 98C shown in FIG. 9 , a facility 14, a SOP 39 or a portion of an SOP 39, a manual tool or group of manual tools as shown in FIGS. 17-20 , etc.
  • the data can include data generated by a sensor S, for example, by one of the sensors S1...S10 shown in FIG. 2 , where the data generated by the sensor S is generated in response to a performance of an operation Op which is performed by the machine 16.
  • data generated by the sensor S can include, as described herein, a condition state and/or an operating parameter of the operation performed by the machine 16, which may include a condition state and/or parameter of an element E, for example, a condition state and/or parameter of one of the elements E1...E10 sensed by one of the sensors S1...S10 as shown in FIG. 2 .
  • data generated by the sensor S can include a condition state and/or a parameter of one or more stations ST of the machine 16 sensed by the sensor S, such as stations ST1...ST10 shown in FIG. 2 .
  • Other data generated by the sensor S can include parameters of the machine 16 such as operating temperatures, pressures, cycle counts, current, voltage, etc. sensed by the sensor S.
  • Data generated by the systems SY and stored to the data storage memory 90 for populating the display template 138 can include, by way of non-limiting example, an inventory level of a supplier part, a tool, a machine component, etc., a production count of units produced, units in process, etc., a condition status of material handling equipment or other facility infrastructure status, such as temperatures, humidity levels, etc. in various locations in the facility, an equipment status, etc.
  • the data is collected and stored to the data storage memory 90 in real time, such that the server, e.g., the facility server L3 in the present example, can populate a display template 137 to generate a data display 138 in real time.
  • the term "in real time” as used herein refers to a level of responsiveness by computing equipment included in the enterprise 12, including, for example, base layer controllers L1, machine controllers L2, facility controllers L3, enterprise controller L4, data storage memory 90, user devices U, etc., which is perceived by a user as sufficiently immediate such that the response of the computing equipment in collecting and displaying data in a data display 138 is without delay, e.g., is perceived to occur at substantially the same time and at the same rate as the time and rate of the data being displayed.
  • data is collected from the sensors S and the systems SY in real time, e.g., without delay, such that the data can be populated into a display template 137 and displayed as a data display 138 on a user device U in real time, e.g., such that the data displayed on the data display 138 is displayed sufficiently immediate to the generation of that data by the originating source (for example, by a sensor S), that a user can view the data displayed in a data display 138 immediate to the time the data is generated and/or immediate to the time the event from which the data is generated occurs, for example, immediate to the time an operation is performed by a machine 16.
  • Data when collected and stored in the data memory storage 90, can be associated in the data memory storage 90, for example, in a data matrix provided for that purpose, with identifying information, which can include the source of the data such as the identification of the sensor generating the data, the condition state and/or the parameter represented by the data, e.g., the data feature 141 corresponding to the data, one or more of the operation Op, machine 16, element E, zone 98, facility 12, and/or system SY associated with the data, and a data time associated with the data.
  • the data time associated with the data can be one of a time the data was generated, e.g., the time the data was sensed by a sensor generating the data, and a time the data was stored to the data memory storage.
  • the time the data was sensed and the time the data was stored should be substantially equal as these events are immediate to each other in the real time system described herein.
  • the example is non-limiting, and it would be understood that another time, such as a timestamp applied by a controller such as a base layer controller L1 or machine controller L2, can be used as the data time.
  • the display template 137 includes at least one data feature 141, where a data feature 141 may be defined by the type and origin of the data displayed by the data feature 141.
  • a data feature 141 may be defined by the type and origin of the data displayed by the data feature 141.
  • the data display 141 in the present example configured as the SOP timeline display 33, includes a first data feature 141 which is a baseline cycle indicator 29 for displaying a baseline cycle of each of the operations Op 1...Op10 of the SOP 39 shown in FIG. 3 .
  • the SOP timeline display 33 includes a second data feature 141 which is an actual cycle indicator 31 for displaying an actual cycle of each of the operations Op1...Op10.
  • the SOP timeline display 33 can be generated by the facility server L3 in real time, such that the SOP timeline display 33 will continuously update the displayed data features 141 in real time as sensor data is generated by one of more sensors S sensing the condition state of elements E1...E7 as the operations Opl...Op9 are performed in real time.
  • the actual time 37 is displayed and can be considered a data feature 141 of the SOP timeline display 33 at 37, such that a user viewing the data display 141 (the SOP timeline display 33 in the present example) would perceive the data updating in real time, to show the condition state of each operation Op1...Op9 as sensed by a corresponding sensor S at the actual time 37 displayed on the data display 138. As shown in FIG.
  • At least one of the data features 141 can include a differentiator 142 to differentiate in data features in real time based on the data populating the display template 137 at that time.
  • the second data feature 141 e.g., the actual cycle indicator 31
  • the second data feature 141 includes a differentiator 142 to differentiate the mode 143 of the actual cycle indicator 31 in real time.
  • actual cycle indicator 31 (the second data feature 141 in the present example) can be displayed in one of a "green” mode and a "red” mode, where the differentiator 142 in this example is the color (red or green) displayed by the actual cycle indicator 31.
  • a data feature 141 displayed in "green” mode indicates the data feature 141 is in tolerance at the time the data display 138 is generated
  • a data feature 141 displayed in "red” mode indicates the data feature 141 is out of tolerance at the time the data display 138 is generated.
  • the actual cycle indicator 31 for operation Op5 is displayed in "green” mode to indicate that at the time the data display 138 was generated, e.g., at time "22:36:24 and 600 milliseconds" as indicated by actual time 37 shown in FIG. 3 , the condition state sensed by a sensor S for operation Op5 was within tolerance limits set for operation Op5.
  • the mode in which the actual cycle indicator 31 (the data feature 141) is displayed would change from "green” mode to "red” mode at any time the actual cycle of the operation being performed by operation Op5 was sensed to be out of tolerance, and would revert to "green” mode at any time the actual cycle of the operation being performed by operation Op5 was sensed to be in tolerance, such that a user viewing the data display 138, e.g., the SOP timeline display 33 in the present example, could monitor the condition of the operation Op5 in real time.
  • FIGS. 3, 4 , 6-8 and FIGS. 10-20 is illustrative of a display template 137 and data display 138 which can be generated by a server such as facility server L3 or enterprise server L4 using data generated by and/or within the enterprise 12, including data generated by a machine 16 and/or a system SY, and/or data stored in data memory storage 90, e.g., data collected and/or compiled by AOS 10.
  • the illustrative examples are non-limiting and it would be understood that the display templates 137 shown herein as data populated data displays 138 are representative of only a portion of the display templates 137 which can be generated by the system described herein and/or using data of an AOS 10.
  • an example display template 137 shown as a data populated data display 138 is shown, where the data display 138 is arranged as a heartbeat display 35.
  • the heartbeat display 35 shows a SOP 39 displayed on the horizontal axis (as shown on the page).
  • a heartbeat 88 of the SOP 39 is shown as a first data feature 141 of the heartbeat display 35
  • an actual cycle indicator 31 is shown as a second data feature 141 displayed by the heartbeat display 35, where an actual cycle indicator 31 is shown for each of the operations Op1...Op9 of the SOP 39.
  • the second data feature 141 e.g., the actual cycle indicator 31, is a differentiated data feature 142 differentiated by the color of the vertical bar displaying the actual cycle indicator 31.
  • the differentiated data feature 142 (the actual cycle indicator 31) is displayed in one or the other modes 143 which in the example include a "green" mode when the actual cycle indicator 31 is within a predetermined tolerance for a respective one of the operations Opl...Op9 at the actual time the heartbeat display 35 is generated, and includes a "red” mode when the actual cycle indicator 31 is outside a predetermined tolerance, where the mode 143 displayed for the actual cycle indicator 31 of a respective operation Op1...Op9 is determined by the sensor data generated by the sensor S sensing the actual cycle condition of the respective operation Opl...Op9 at the immediate, e.g., actual time the heartbeat display 35 is generated.
  • an example display template 137 shown as a data populated data display 138 is shown, where the data display 138 is arranged as a heartbeat display 35.
  • the heartbeat display 35 shows a SOP 39 displayed on the horizontal axis (as shown on the page).
  • a heartbeat 88 of the SOP 39 is shown as a first data feature 141 of the heartbeat display 35, and an actual cycle indicator 31 is shown as a second data feature 141 displayed by the heartbeat display 35, where an actual cycle indicator 31 is shown for each of the operations Op1...Op9 of the SOP 39.
  • the second data feature 141 is a differentiated data feature 142 differentiated by the color of the vertical bar displaying the actual cycle indicator 31 (shown in the figure as shading indicating colors by name for clarity of illustration).
  • the differentiated data feature 142 (the actual cycle indicator 31) is displayed in one or the other modes 143 which in the example include a "green" mode (displayed in a green color but shown in the figure by shading for clarity of illustration) when the actual cycle indicator 31 is within a predetermined tolerance for a respective one of the operations Op1...Op9 at the actual time the heartbeat display 35 is generated, and includes a "red” mode (displayed in a red color but shown in the figure by shading for clarity of illustration) when the actual cycle indicator 31 is outside a predetermined tolerance, where the mode 143 displayed for the actual cycle indicator 31 of a respective operation Op1...Op9 is determined by the sensor data generated by the sensor S sensing the actual cycle condition of the respective operation Opl...Op9 at the immediate, e
  • an example display template 137 shown as a data populated data display 138 is shown, where the data display 138 is arranged as a cycle state display including a SOP cycle state display 13 and a heartbeat cycle state display 11.
  • the SOP cycle state display 13 shows a SOP 39 displayed on the vertical axis (as shown on the page), including operations Opl...Op4.
  • a baseline cycle indicator 29 is shown as a first data feature 141 of the SOP cycle state display 13
  • an actual cycle indicator 31 is shown as a second data feature 141 displayed by the SOP cycle state display 13, where an actual cycle indicator 31 is shown for each of the operations Opl...Op4 of the SOP 39.
  • the second data feature 141 e.g., the actual cycle indicator 31, is a differentiated data feature 142 differentiated by the color of the vertical bar displaying the actual cycle indicator 31.
  • the differentiated data feature 142 (the actual cycle indicator 31) is displayed in one of a plurality of modes 143 which in the example include "green”, “gold”, “purple”, “yellow” and “red” modes, each representing a different operating condition of the actual cycle of the respective operation Opl...Op4.
  • the mode displayed by the actual cycle indicator 31 for each operation Opl...Op4 indicates the condition state of that operation sensed by a sensor S at the immediate time the data display 138 shown in FIG. 7 was generated.
  • the actual cycle indicators 31 for operations Op1 and Op2 are displayed in the "gold” mode, indicating, for example, that these two operations are in a "starved” cycle state corresponding to the "gold” mode.
  • the "green” mode can indicate an operation is in “auto” cycle state
  • the "red” mode can indicate the operation is in a “faulted” cycle state
  • the “purple” mode can indicate the operation is in a “blocked” cycle state
  • the "yellow” mode can indicate the operation is in a "stopped” cycle state.
  • the heartbeat cycle state display 11 included in the data display 138 and shown at the bottom portion of the user interface 74 includes a heartbeat display 11 of the cycle times of each of a series of performances of the SOP 39 displayed in chronological order by cycle bars 15, with the last (far right as shown on the page) cycle bar 15 corresponding to the actual, e.g., immediate time the data display 137 shown in FIG. 7 was generated, e.g., as shown on the figure, at 9:06:40 pm on 5/5/14.
  • the cycle bar 15 is shown as a data feature 141, and is a differentiated data feature 142, where the cycle bar 15 is a stacked bar, using the same modes 143 defined for the SOP cycle state display 13, the amount of time in each performance of the SOP 39, e.g., in each fully operational cycle of the SOP 39, the time spent in each of the modes 143.
  • a cycle bar 15A is displayed in the "yellow" mode as a stopped cycle state.
  • a cycle bar 15B is displayed as a stacked bar with each bar segment of the stacked bar shown in a different mode 143 indicating for approximately half of the operational cycle time represented by the cycle bar 15B the machine 16 was in a "green" (auto cycle state) mode, approximately one quarter of the operational cycle time represented by the cycle bar 15B the machine 16 was in a "gold” (starved cycle state) mode, and approximately one quarter of the operational cycle time represented by the cycle bar 15B the machine 16 was in a "yellow” (stopped cycle state) mode.
  • a subsequent (in time) cycle bar 15C is displayed in “green” (auto) mode and yet another subsequent (in time) cycle bar 15D is displayed in "yellow” (stopped cycle state) mode, where each of these colors is shown in the figure as shading corresponding to the color name shown in the legend of modes 143 or clarity of illustration.
  • the heartbeat cycle state display 11 included in the data display 138 of FIG. 7 is shown at the bottom portion of the user interface 74 (as shown on the page).
  • the data template 137 defines a user interface element (UIE) 86 associated with each of the vertical cycle bars 15. For clarity of illustration, only one of the UIE 86 associated with one of the cycle bars 15 is shown.
  • UIE user interface element
  • a user applying a touch input to the UIE 86 activates the display template 137 to display the additional information shown in the upper portion of the user interface 74 (as shown on the page), where the additional information included a magnified (zoomed in) view 17 of the cycle bar 15B, and further textual descriptions and/or labels 19A, 19B, and 19C identifying each of the bar segments of the cycle bar 15B by cycle state, e.g., as "normal", "blocked” and "starved.”
  • each of the labels 19A, 19B, 19C may be associated by the display template 137 with a UIE 86, such that a touch input to one of the labels 19 can activate the display template 137 to display additional details of the condition states associated with each bar segment on the data display 138.
  • a digital marker 101 is displayed to mark a specific one of the cycle bars 15.
  • the digital marker 101 is used to identify the operational cycle of the machine where a corrective action was taken in response to the blocked condition occurring in the operational cycle represented by the cycle bar 15B.
  • the modes 143 displayed for the cycle bars 15 subsequent (in time) to the cycle bar 15 marked by the marker 101, can be monitored to determine, for example, the effectiveness of the corrective action taken earlier.
  • an example display template 137 shown as a data populated data display 138 is shown in each of FIGS. 10-12 , where the data display 138 in each example is arranged as a production system display for showing stoppages in each of four zones 98 (Zone 1 through Zone 4) in a plant assembly area, using a different display template 137 for generating each of the three different production system displays 106A, 106B 106C.
  • the production system display 106 can also be referred to as a stoppage time display.
  • the production system displays 106A, 106B, 106C each display stoppage data sensed for automatic guided vehicles (AGVs) (not shown) used to move products from one station ST to the next station ST in an assembly area within each zone 98, where it is desirable that each AGV moves continuously without stoppage through every station ST in the zone.
  • a zone can be, for example, a zone such as zones 98A, 98B, 98C shown in FIG. 9 , where each zone 98A, 98b, 98C is configured similarly such that comparison of the stoppage time in one zone 98 to another zone 98 facilities identification and prioritization of top causal factors for corrective action and/or best practices for replication across the zones. Referring to FIG.
  • the production system display 106A displays data collected in a current production shift for each of zone 1 through zone 4, where the data is displayed in real time at the actual time during the production shift when the data display 106A is generated.
  • a vertical bar 107 representing cumulative starved time during a shift is shown as a first data feature 141 in the present example.
  • Starved time includes stoppage time of AGVs in the zone 98 which is caused by a starved state, for example, due to a parts shortage.
  • vertical bars 108 representing other stoppage time of AGVs in the zone is shown as a second data feature 141 which is displayed for each hour in the shift.
  • stoppage time includes stoppage time caused by causes other than blocked or starved, such as a quality system (QS) stop, a tool stop, a zone safe stop, and/or a miscellaneous stop.
  • QS quality system
  • each stoppage can be grouped as micro (less than 30 seconds) minor (between 30 seconds to 2 minutes) and/or major (over 2 minutes) stops.
  • a vertical bar 109 representing cumulative blocked time during the shift is shown as a third data feature 141.
  • Blocked time includes stoppage time of AGVs in the zone which is caused by a blocked state, for example, due to stoppage of an AGV in a downstream station.
  • Each of the first, second and third data features 141 in the present example is also a differentiated feature 142, differentiated in the present example by color (shown in the figure as shading indicating colors by name for clarity of illustration), where in the present example the "yellow” mode 143 indicates starved time, the "gold” mode 143 indicates other stoppage time, and the "blue” mode 143 indicates blocked time.
  • a top causal factor display 111 is shown, also referred to as a hotspots display 111 showing the top causal factors of stoppage time.
  • the top causal factor of stoppage time is QS (quality system) stop time occurring in station 350 of sub-zone 3A of zone 3, and the data feature 141, the horizontal bar (as shown in the figure) showing total stoppage time for this causal factor of 9.67 seconds, is a differentiated factor 142 displayed in the "gold" mode 143 indicating the top causal factor is other stoppage time, specifically QS stop time, in station 350.
  • QS quality system
  • the production system display 106B displays the data using first, second and third differentiated data features 141, 142, where in the example shown in FIG. 11 , the stoppage time due to other causes, e.g., data feature 108, is shown as an accumulated duration for the shift being displayed, accumulated over the shift time until the actual time the data display 138, e.g., the stoppage time display 106B is generated in real time.
  • the stoppage time due to other causes e.g., data feature 108
  • the production system display 106C includes a first data display 113 of stoppage time (as a first data feature 141) displayed for a station ST, such as station ST300 of sub-zone 2D in the present example, displayed by hour using a vertical stacked bar (as shown on the page) which is a differentiated data feature 142 displaying each of the bar segments of each stacked bar in a mode 143 corresponding to the type of stoppage time displayed by the bar segment.
  • the modes 143 shown in stoppage time by station display 113 include "tool stop", "zone safe” and "QS stop", each mode 143 differentiated by shading for clarity of illustration in the figures.
  • a stoppage time display by type 112 shows the distribution of stoppage time accumulated in the current production shift in a pie chart arranged by type of stoppage time, where the data feature 141 shown as a percentage of total time is differentiated such that each pie portion of the pie chart 112 is displayed in a different mode 143.
  • a top causal factor by mode display 114 is shown, showing in a display of horizontal bars (as shown on the page) the cumulative stoppage time for each of the causes of stoppage.
  • Non-differentiated data features 141 are displayed in the data display 138 shown in FIG. 12 , such as the matrix of stoppage times by cause and hour of shift production.
  • FIGS. 13-16 an example display template 137 shown as a data populated data display 138 is shown in each of FIGS. 13-16 , where the data display 138 in each example is arranged as a digitized asset display 106 for showing one or more data features 141 which are digitized representations of an asset in a system such as enterprise 12.
  • An asset can be any asset of the enterprise 12, such as an element E, sensor S, power source P, server L3, L4, controller L1, L2, machine 15, an asset of a facility 14, etc.
  • Non-limiting illustrative examples of an asset can be a robot, a tool, a tool tray, a torque wrench, a computer numerically controlled (CNC) machine, an AGV, an elevator in a building, etc. or any other tool, machine M, element E, or object that performs a set of tasks.
  • the set of tasks performed by an asset can be included in an SOP 39. Referring to FIG.
  • a display template 137 shown as a data populated data display 138 is shown as a digitized asset display 45, where a singular asset is displayed using a plurality of data features 141 including an asset identification number 47, a current active group name 57, and a pallet and/or AGV number 53 to which the asset identified by the identification number 47 is associated and, for example, is being transport by from one station ST to another station ST in a production line, as shown in FIG. 15 in an area dashboard display 75 of a production line.
  • the digitized asset display 45 includes additional data features 141 which are related to a condition state and/or operation or task status of the asset having the asset identification number 47, shown in the present example as asset number "30".
  • a current cycle running time 49, a current group running time 51, an accumulated time for over cycle time for a current shift 59, and a ratio 55 of accumulated number of over cycle cycles (xx) to the total cycle count (yy) for a current shift are show as data features 141 of the digitized asset display 45 shown in FIG. 13 .
  • a number of the data features 141 are differentiated features 142 displayed in one of the modes 143, e.g., differentiated by display in one of a "green” mode, a "yellow” mode, and an "orange” mode.
  • the differentiated features 142 include features 49, 51 and 53 in the present example.
  • a digitized asset status feature 43 is shown as a differentiated border surrounding the other data features, and displays an overall status and/or condition state 43 of the digitized asset, which in the present example is identified as asset number 30, by displaying the condition state 43 (the border) in one of the modes 143 shown in FIG. 13 .
  • the condition state 43 of the digitized asset number 30 shown in the digitized asset display 45 is displayed in "green" mode.
  • FIG. 14 shows a data display 138 arranged as a multiple asset display 65, including multiple digitized asset displays 45A...45F. In the example shown in FIG.
  • a UIE 86 is defined by the display template 137 for data feature 55 of the digitized asset display 45, such that a touch input by a user viewing the data display 65 on a user interface 74 of a user device U would activate the display template 137 to generate and display a pop-up window 61 providing additional information, which in the present example includes model, part and tool number information for the digitized asset having identification number 30 and represented by the digitized asset display 45C.
  • FIG. 15 shows a display template 137 and data display 138 arranged as an area dashboard display 75 including an area display 81 including multiple differentiated data features 142 which are displayed in one of the modes 143A associated with the area display 81 and displayed in a legend 77, and further includes a production by zone display 87, which is one a plurality of production tracking displays 83 (see FIG. 16 ) which can be displayed in the bottom portion (as shown on the page) of the area dashboard display 75.
  • a user can provide a touch input to the user interface 74, such as a swipe action, to alternate, e.g., switch the production tracking display 83 shown in the bottom portion of the dashboard display 75 between the various production tracking displays 85, 87, 89 shown in FIG. 16 .
  • the production by zone display 87 includes multiple differentiated data features 142 which are displayed in one of the modes 143B
  • the production by group display 85 includes multiple differentiated data features 142 which are displayed in one of the modes 143C
  • the production by count display 89 includes multiple differentiated data features 142 which are displayed in one of the modes 143D shown in FIG. 16 .
  • the area display 81 shows a graphical representation of a production line including machines 16A, 16B, 16C, each including a subset of stations ST1...ST14. Station ST1 is digitized as a digitized asset 45 shown in FIG.
  • a user can activate the display template 137 by a touch input to one or more of the digitized assets 45 to activate display of a pop-up window 61.
  • FIG. 15 displays digitized assets 45A...45D in zoomed in (expanded) detail in the pop-up window 61.
  • the example shown in FIG. 15 is advantaged by the depth and breadth of detailed information regarding the condition state of the production area shown in the area dashboard 75, including the condition states of the assets within the production area.
  • a user can view the condition state of each of the digitized assets 45 in each of the stations ST in the production line, where each digitized asset 45 is differentiated to display a condition state mode 143A in macro view, and to display multiple condition states in the zoomed in view in the pop-up window 61, for issue identification and resolution.
  • Additional production line condition state information is displayed by the area display 81, using data features 141 such as buffer inventory feature 79 showing an actual unit count of production units over a target buffer unit count in a designated location defined by a buffer zone 71, and incoming material feature 67 showing the condition state of incoming material in an incoming material staging area 69.
  • data features 141 such as buffer inventory feature 79 showing an actual unit count of production units over a target buffer unit count in a designated location defined by a buffer zone 71, and incoming material feature 67 showing the condition state of incoming material in an incoming material staging area 69.
  • FIGS. 17-20 an example display template 137 shown as a data populated data display 138 is shown in each of FIGS. 17-20 , where each of the data displays 138 shown in FIGS. 17-20 relate to the display of manual tool information, thus advantaging AOS 10 by providing a means to collect, digitize and display output from manual tools used in an enterprise 12.
  • manual tools can include non-automated tools such as pneumatically controlled torque wrenches used to tighten fasteners within a predetermined torque range on an assembly line, where, because of the non-automated, e.g., manual operation of the torque wrench, operator variability, etc., real time data collection of condition states of the torque wrench operation can be challenging without the AOS 10 and data display methods described here.
  • FIG. 17 shows a data display 138 arranged as a task group entry display 87 to illustrate entry of manual tools into AOS 10 as a task group that performs the same task one or more times.
  • FIG. 17 shows a task group entry display 87 displaying a system configuration which includes metadata related to an SOP 39 performed in part using manual tools.
  • the manual tools are, where the display of manual tools in the overall system is dictated by the location metadata. In the example shown in FIG.
  • a "Manual Stations" element is created at 93 and lists the manual tools including a first torque tool 001, a second torque tool 002, and a bar code reader 001.
  • first torque tool 001, second torque tool 002, and bar code reader 001 are assigned to station 150 in sub-Zone 2A of Zone 2 in Assembly Area 1 to perform a sequence of tasks including at least one of the torque tools performing the sequence of tasks indicated at 95 in FIG. 17 .
  • the task group entry display 87 can include data features 141 such as a digital indicator 101 which can be lighted or otherwise differentiated indicating the entry of a task to the task sequence 95 was successfully received into the system configuration.
  • FIGS. 19 and 20 display the three manual tools in data displays 138 where FIG. 19 shows a manual tool heartbeat display 99B and FIG. 20 shows a manual tool SOP timeline display 99C, where an actual cycle indicator 31 is displayed in each of the displays 99B, 99C showing the actual cycle duration for each of the manual tools to complete an operational cycle.
  • the operational cycle can require a manual tool to perform multiple tasks during the operational cycle, where the number of tasks completed by the tool in the operational cycle can be displayed as a number encircled in the graphical bar displaying the actual cycle indicator 31.
  • the first torque tool 001 performs six (6) tasks, e.g., for example, torques six (6) fasteners, during its operational cycle.
  • Operational data for the task sequence performed, for example, by one of the torque tools 001 can be displayed in a manual tool analog display 99A shown in FIG. 18 , where the listed tasks are performed in the order listed.
  • differentiated data feature 142 which can be an indicator bar 104
  • the indicator bar 104 can be further differentiated by being displayed in one of the modes 143 shown in FIG. 18 to indicate a condition state of the task associated with the indicator bar 104.
  • the task started at 7:01:34 PM shows the indicator bar 104A displayed in the "green” mode indicating acceptable completion of the "torque satisfied” step.
  • Indicator bar 104B is displayed in the "purple” mode indicating, for example, the angle was not satisfied and re-torquing of the fastener is required.
  • Indicator bar 104C is displayed in "yellow" mode, which could, for example, indicate the task was rejected and/or an alert was set.
  • the manual tool analog display 99A can further include one or more charts 103 for graphically displaying, in the example shown, data related to the trigger pulled signal and the analog signal produced by the manual tools.
  • a user viewing the manual tool displays 99A, 99B, 99C can toggle between the displays 99 and/or activate the display template 137 to update the displays 99 in real time, by selecting the from the tab groupings 144A, 144B shown in FIGS. 18-20 .
  • the user can apply a touch input to the "analog" tab in tab group 144B to view the manual tool analog display 99A in real time, can apply a touch input to the "heartbeat” tab in tab group 144B to view the manual tool heartbeat display 99B in real time, and can apply a touch input to the "sequence" tab in tab group 144B to view the manual tool sequence display 99C in real time.
  • the AOS 10 is advantaged by accumulating the data and inputs from various elements E, machines 16 and facilities 14, and/or over various operating time periods, and analyzing the accumulated data and inputs using a server, such as a facility server L3 and/or the enterprise server L4, to identify issues, trends, patterns, etc.
  • a server such as a facility server L3 and/or the enterprise server L4
  • the AOS 10 described herein is advantaged by the capability to generate a plurality of differently configured data displays 138 generated from a plurality of corresponding display templates 137 populated with real time data which can be displayed to a user in real time, on a user interface 74 of a user device U, to allow real time monitoring of the operation, machine, etc. defining the data display 138 being viewed by the user.
  • Differentiation of certain data features 142 of the data display 138 provides immediate visual recognition by the user/view of the condition state and/or alert status of a differentiated data feature 142.
  • the differentiated data feature 142 may be visually differentiated, for example, by color, pattern, font, lighting, etc. for efficient viewing.
  • the data display 138 may be activated by a touch input to the touch screen 74 to display additional information, for example, in a pop-up window 61, for convenient and real time viewing by the user/viewer.

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  • General Physics & Mathematics (AREA)
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  • Manufacturing & Machinery (AREA)
  • General Engineering & Computer Science (AREA)
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Claims (9)

  1. Ein System (10) zur Automationssteuerung, wobei das System (10) Folgendes umfasst:
    eine Maschine (16), die mindestens einen Sensor (S) aufweist;
    wobei die Maschine (16) so konfiguriert ist, dass sie eine Folge von Arbeitsgängen (39) einschließlich des mindestens einen Arbeitsgangs ausführt;
    den Sensor (S), der so konfiguriert ist, dass er Daten als Reaktion auf die Ausführung des mindestens einen Arbeitsgangs erzeugt;
    einen Datenspeicher (90), der so konfiguriert ist, dass er die von dem mindestens einen Sensor (S) erzeugten Daten empfängt und speichert;
    einen Server (L3), der mit dem Datenspeicher (90) kommuniziert;
    wobei der Server (L3) mindestens eine Anzeigevorlage (137) für die Anzeige der Daten enthält;
    wobei die mindestens eine Anzeigevorlage (137) mindestens ein Datenmerkmal (141) enthält,
    das durch den mindestens einen Arbeitsgang und die Daten definiert wird;
    wobei die mindestens eine Anzeigevorlage (137) mindestens ein durch Berührung aktiviertes Benutzeroberflächenelement (74) - das UIE (User Interface Element) (86) - definiert, das dem mindestens einen Datenmerkmal (141) zugeordnet ist;
    wobei das mindestens eine Datenmerkmal (141) ein Differenzierungsmerkmal (142) aufweist, um das mindestens eine Datenmerkmal (141) in einem Modus anzuzeigen, bei dem es sich entweder um einen ersten Modus oder um mindestens einen zweiten Modus handelt;
    wobei der Modus des mindestens einen Datenmerkmals (141) durch die Daten bestimmt wird, welche die Datenanzeige (138) füllen;
    wobei der Server (L3) so konfiguriert ist, dass er aus dem Datenspeicher (90) die mindestens eine Anzeigevorlage (137) abruft und:
    die Datenanzeige (138) in Echtzeit generiert, indem:
    die mindestens eine Anzeigevorlage (137) mit den von dem mindestens einen Sensor (S) in Echtzeit erzeugten Daten gefüllt wird; und
    das mindestens eine Datenmerkmal (141) in dem in Echtzeit bestimmten Modus des mindestens einen Datenmerkmals (141) angezeigt wird; und
    eine Anzeige von zusätzlichen Informationen in Echtzeit als Reaktion auf die Aktivierung des UIE generiert, wenn diese von einem Benutzer berührt wird;
    wobei die Anzeige zusätzlicher Informationen eine Vielzahl digitalisierter Anlagenkomponenten und mehrere Bedingungszustände der digitalisierten Anlagenkomponenten umfasst;
    ein Benutzergerät (U) mit einer Benutzeroberfläche (74);
    wobei das Benutzergerät (U), das mit dem Server (L3) kommuniziert, die Datenanzeige (138) in Echtzeit empfängt und auf der Benutzeroberfläche (74) anzeigt;
    wobei die Benutzeroberfläche (74) als Touch-Oberfläche ausgeführt ist, auf der ein Benutzer das UIE berühren kann;
    wobei, wenn das UIE durch die Berührung durch den Benutzer aktiviert wird, die Anzeigevorlage (137) aktiviert wird, so dass auf der Datenanzeige (138) die zusätzlichen Informationen (141) mittels eines Pop-up-Fensters und das mindestens eine Datenmerkmal (141) in Echtzeit angezeigt werden;
    wobei
    der mindestens eine Arbeitsgang durch eine Basis-Zykluszeit gekennzeichnet ist;
    der mindestens eine Sensor (S) so konfiguriert ist, dass er als Reaktion auf die Ausführung des mindestens einen Arbeitsgangs Daten erzeugt, indem die Ausführung eines tatsächlichen Zyklus des mindestens einen Arbeitsgangs erfasst wird und in Echtzeit die Daten erzeugt werden, die durch die Ausführung des tatsächlichen Zyklus des mindestens einen Arbeitsgangs definiert werden; und
    wobei die mindestens eine Anzeigevorlage (137) Folgendes umfasst:
    die von der Maschine (16) ausgeführte Folge von Arbeitsgängen SOP (Sequence of Operations);
    einen Basis-Zykluszeitindikator zur Anzeige der Basis-Zykluszeit des mindestens einen Arbeitsgangs;
    einen Ist-Zykluszeitindikator zur Anzeige einer Ist-Zykluszeit des tatsächlichen Zyklus, der durch den mindestens einen Arbeitsgang ausgeführt wird;
    wobei der Ist-Zykluszeitindikator mit den von dem Sensor (S) erzeugten Daten gefüllt wird; und
    wobei der Ist-Zykluszeitindikator so differenziert wird, wie sich dies aus einem Vergleich der Ist-Zykluszeit mit der Basis-Zykluszeit des mindestens einen Arbeitsgangs ergibt.
  2. Das System (10) nach Anspruch 1, wobei die durch die Ausführung des Arbeitsgangs definierten Daten einen Bedingungszustand des Arbeitsgangs und/oder einen Arbeitsgangparameter des mindestens einen Arbeitsgangs aufweisen;
    wobei der Bedingungszustand und/oder der Arbeitsgangparameter durch den mindestens einen Sensor (S) während der Ausführung des mindestens einen Arbeitsgangs erfasst wird.
  3. Das System (10) nach Anspruch 1, wobei die Daten im Datenspeicher (90) dem mindestens einen Arbeitsgang, der Maschine (16) und einer Datenzeit zugeordnet sind;
    wobei der den Daten zugeordnete Datenzeitpunkt entweder ein Zeitpunkt ist, zu dem der m indestens eine Sensor (S) die Daten erfasst hat, oder ein Zeitpunkt, an dem die Daten im Datenspeicher (90) gespeichert wurden.
  4. Das System (10) nach Anspruch 1, wobei die Anzeigevorlage (137) den Basis-Zyklusindikator und den Ist-Zyklusindikator in einer SOP-Zeitleistenanzeige anzeigt.
  5. Das System (10) nach Anspruch 1, wobei die Anzeigevorlage (137) den Basis-Zyklusindikator und den Ist-Zyklusindikator in einer "Heartbeat"-Zeitleistenanzeige anzeigt.
  6. Das System (10) nach Anspruch 1, wobei das mindestens eine Datenmerkmal (141) ferner Folgendes umfasst: ein Stillstandszeitmerkmal.
  7. Das System (10) nach Anspruch 1, das ferner umfasst:
    das mindestens eine Datenmerkmal (141), das ein digitalisiertes Anlagenkomponentenmerkmal ist.
  8. Ein Verfahren zur Automationssteuerung, wobei das Verfahren Folgendes umfasst:
    Ausführung einer Folge von Arbeitsgängen (39), die mindestens einen Arbeitsgang einschließt, bei dem eine Maschine (16) verwendet wird, die mindestens einen Sensor (S) aufweist;
    Erzeugung von Daten als Reaktion auf die Ausführung des mindestens einen Arbeitsgangs unter Verwendung des Sensors (S);
    Empfangen und Speichern der von dem mindestens einen Sensor (S) erzeugten Daten in einem Datenspeicher (90);
    Erzeugung einer Datenanzeige (138) in Echtzeit unter Verwendung eines Servers (L3), der mit dem Datenspeicher (90) kommuniziert, durch:
    Abrufen einer Anzeigevorlage (137) aus dem Datenspeicher (90);
    Ausfüllen der Anzeigevorlage (137) mit den von dem mindestens einen Sensor (S) in Echtzeit erzeugten Daten, um daraus die Datenanzeige (138) zu erzeugen;
    wobei die Anzeigevorlage (137) mindestens ein Datenmerkmal (141) umfasst, das durch den mindestens einen Arbeitsgang und die Daten definiert wird;
    wobei die mindestens eine Anzeigevorlage (137) mindestens ein durch Berührung aktiviertes Benutzeroberflächenelement - das UIE (86) - definiert, das dem mindestens einen Datenmerkmal (141) zugeordnet ist;
    wobei das mindestens eine Datenmerkmal (141) ein Differenzierungsmerkmal (142) aufweist, um das mindestens eine Datenmerkmal (141) in einem Modus anzuzeigen, bei dem es sich entweder um einen ersten Modus oder um mindestens einen zweiten Modus handelt;
    wobei der Modus des mindestens einen Datenmerkmals (141) durch die Daten bestimmt wird, mit denen die Datenanzeige (138) gefüllt ist;
    wobei die Datenanzeige (138) in Echtzeit auf einer Benutzeroberfläche (74) eines Benutzergeräts (U) erscheint, das mit dem Server (L3) kommuniziert, so dass das mindestens eine Datenmerkmal (141) in dem in Echtzeit bestimmten Modus (143) des mindestens einen Datenmerkmals (141) angezeigt wird;
    wobei eine Anzeige von zusätzlichen Informationen in Echtzeit als Reaktion darauf erzeugt wird, dass das UIE (86) durch Berührung durch einen Benutzer aktiviert wird;
    wobei die Anzeige zusätzlicher Informationen eine Vielzahl von digitalisierten Anlagenkomponenten und mehrere Bedingungszustände der digitalisierten Anlagenkomponenten umfasst;
    wobei über die Benutzeroberfläche (74) die Berührung aufgenommen wird, die der Benutzer auf der durch Berührung aktivierten Benutzeroberfläche UIE (86) ausführt, welche durch die Anzeigevorlage (137) definiert wird; und
    die Anzeigevorlage (137) über die Berührung der UIE (86) durch den Benutzer aktiviert wird;
    wobei die Aktivierung der Anzeigevorlage (137) die Anzeige der zusätzlichen Informationen (141) in der Datenanzeige mittels eines Pop-up-Fensters und des mindestens einen Datenmerkmals (141) auf der Benutzeroberfläche (74) in Echtzeit als Reaktion auf die Berührung durch den Benutzer umfasst;
    wobei die zusätzlichen Informationen durch den Modus des mindestens einen Datenmerkmals (141) in Echtzeit definiert werden,
    wobei
    der mindestens eine Arbeitsgang durch eine Basis-Zykluszeit gekennzeichnet ist;
    der mindestens eine Sensor (S) so konfiguriert ist, dass er Daten als Reaktion auf die Ausführung des mindestens einen Arbeitsgangs erzeugt, indem er die Ausführung eines tatsächlichen Zyklus des mindestens einen Arbeitsgangs erfasst und die durch die Ausführung des tatsächlichen Zyklus des mindestens einen Arbeitsgangs definierten Daten in Echtzeit erzeugt; und
    wobei die mindestens eine Anzeigevorlage (137) Folgendes umfasst:
    die von der Maschine (16) ausgeführte Folge von Arbeitsgängen SOP;
    einen Basis-Zykluszeitindikator für die Anzeige der Basis-Zykluszeit des mindestens einen Arbeitsgangs;
    einen Ist-Zykluszeitindikator für die Anzeige einer Ist-Zykluszeit des tatsächlichen Zyklus, der durch den mindestens einen Arbeitsgang ausgeführt wird;
    wobei der Ist-Zykluszeitindikator mit den vom Sensor (S) erzeugten Daten gefüllt wird; und
    wobei der Ist-Zykluszeitindikator so differenziert wird, wie sich dies aus einem Vergleich der Ist-Zykluszeit mit der Basis-Zykluszeit des mindestens einen Arbeitsgangs ergibt.
  9. Das Verfahren nach Anspruch 8, wobei das Verfahren ferner umfasst:
    Bestimmung eines Bedingungszustands der Daten, mit denen das mindestens eine Datenmerkmal (141) gefüllt wird;
    Auswahl entweder des ersten Modus oder des mindestens zweiten Modus auf der Grundlage des Bedingungszustands;
    und
    Anzeige des mindestens einen Datenmerkmals (141) in dem ausgewählten Modus, d. h. entweder dem ersten Modus oder dem mindestens zweiten Modus.
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CN109507943B (zh) 2022-01-11
US11347194B2 (en) 2022-05-31
CN106415415B (zh) 2020-07-24
US11640151B2 (en) 2023-05-02
EP3223092A1 (de) 2017-09-27
EP3223092B1 (de) 2020-09-02

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